Results for “Engineer” — Page 52

DOE OSTI2025

CFD modeling of near-wall combustion and unburned methane prediction in natural gas spark ignition engines

Natural gas-powered engines play a critical role in gas drilling, compression, and transmission sectors, but methane (CH 4 ) from engine combustion slip can be significant over their lifespan, contributing to atmospheric pollution and signaling reduced engine efficiency. Here, to address this challenge, computational fluid dynamics (CFD) simulations offer valuable insights into the in-cylinder combustion process, enabling the optimization of combustion strategies and engine designs to minimize unburned CH 4 slip. This study aims to evaluate and improve combustion models for simulating the combustion process and predicting unburned CH 4 concentrations in natural gas spark-ignition (SI) engines, including engines that are part of combined reformer-engine systems. Specifically, the performance of two flamelet-based combustion models—the Extended Coherent Flame Model (ECFM) and the G-equation model—was assessed using experimental engine data collected under varying excess-air ratio (λ) conditions and fuel compositions, including natural gas and syngas blends. In addition, to enhance the predictive capabilities of the G-equation model, a flame-wall interaction (FWI) sub-model was integrated into its framework. The effects of its model parameters, such as quenching and influence distance, on combustion behavior and unburned methane predictions were analyzed in detail. The ECFM tended to predict delayed combustion phasing under diluted mixture conditions, resulting in overprediction of unburned CH 4 concentrations. In contrast, the G-equation model provided reasonable predictions of combustion pressure, while representing higher the CH 4 reduction rate across the operating condition compared to experimental data. Incorporating the FWI sub-model—with the quenching distance calculated based on a pressure-dependent relation (P -0.48 ) and a fixed influence distance of 1.5 mm—further improved the G-equation model’s accuracy in predicting CH 4 reduction rates without compromising its ability to simulate the combustion process.

Combustion model↗

DOE OSTI2019

Experimental Study and Model Predictive Control of a Lean-Burn Gasoline Engine Coupled With a Passive Selective Catalytic Reduction System

Lean-burn gasoline engines have reflected 10–20% engine efficiency gain over stoichiometric engines and are widely considered as a promising technology for meeting the 54.5 miles-per-gallon (mpg) corporate average fuel economy standard by 2025. Nonetheless, nitrogen oxides (NO x ) emissions control for lean-burn gasoline for meeting the stringent Environmental Protection Agency tier 3 emission standards has been one of the main challenges toward the commercialization of highly efficient lean-burn gasoline engines in the United States. Passive selective catalytic reduction (SCR) systems, which consist of a three-way catalyst (TWC) and SCR, have demonstrated great potentials of effectively reducing NO x emissions for lean gasoline engines at low cost. Yet, passive SCR operation may cause significant fuel penalty since rich engine combustion is required for ammonia generation. The purpose of this study is to develop a model-predictive control (MPC) scheme for a lean-burn gasoline engine coupled with a passive SCR system to minimize the total equivalent fuel penalty associated with passive SCR operation while satisfying stringent NO x and ammonia (NH 3 ) emissions requirements. Simulation results demonstrate that the MPC approach can reduce the fuel penalty by 43.9% in a simulated US06 cycle and 28.0% in a simulated urban dynamometer driving schedule (UDDS) cycle, respectively, compared to the baseline control, while achieving over 97% DeNO x efficiency and less than 15 ppm tailpipe ammonia slip. The proposed MPC controller can potentially enable highly efficient lean-burn gasoline engines while meeting the stringent Environmental Protection Agency tier 3 emission standards.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

CONTROLLED END GAS AUTO IGNITION WITH EXHAUST GAS RECIRCULATION ON A STOICHIOMETRIC, SPARK IGNITED, NATURAL GAS ENGINE

The goal of this study is to address fundamental limitations to achieving diesel-like efficiencies in heavy duty on-highway natural gas (NG) engines. Engine knock and misfire are barriers to pathways leading to higher efficiency engines. This study explores enabling technologies for development of high efficiency stoichiometric, spark ignited, natural gas engines. These include design strategies for fast and stable combustion and higher dilution tolerance. Additionally, advanced control methodologies are implemented to maintain stable operation between knock and misfire limits. To implement controlled end- gas autoignition (C-EGAI) strategies a Combustion Intensity Metric (CIM) is used for ignition control with the use of a Woodward large engine control module (LECM). Tests were conducted using a single cylinder, variable compression ratio, cooperative fuel research (CFR) engine with baseline conditions of 900 RPM, engine load of 800 kPa indicated mean effective pressure (IMEP), and stoichiometric air/fuel ratio. Exhaust gas recirculation (EGR) tests were performed using a custom EGR system that simulates a high pressure EGR loop and can provide a range of EGR rates from 0 to 40%. The experimental measurements included the variance of EGR rate, compression ratio, engine speed, IMEP, and CIM. These five variables were optimized through a Modified Box- Benken design Surface Response Method (RSM), with brake efficiency as the merit function. A positive linear correlation between CIM and f-EGAI was identified. Consequently, CIM was used as the feedback control parameter for C-EGAI. As such, implementation of C-EGAI effectively allowed for the utilization of high EGR rates and CRs, controlling combustion between a narrower gap between knock and lean limits. The change from fixed to parametric ignition timing with CIM targeted select values of f-EGAI with an average coefficient of variance (COV) of peak pressure of 5.4. The RSM efficiency optimization concluded with operational conditions of 1080 RPM, 1150 kPa IMEP, 10.55:1 compression ratio, and 17.8% EGR rate with a brake efficiency of 21.3%. At this optimized point of peak performance, a f-EGAI for C-EGAI was observed at 34.1% heat release due to auto ignition, a knock onset crank angle value of 10.3° aTDC and ignition timing of - 24.7° aTDC. This work has demonstrated that combustion at a fixed f-EGAI can be maintained through advanced ignition control of CIM without experiencing heavy knocking events.

Cooperative Fuel Research Engine, Auto Ignition, E↗

DOE OSTI2021

Solid particulate mass and number from ducted fuel injection in an optically accessible diesel engine in skip-fired operation

Ducted fuel injection (DFI) is a new combustion strategy that has been shown to significantly attenuate soot formation in diesel engines. While previous studies have used optical diagnostics and optical filter smoke number methods to show that DFI reduces in-cylinder soot formation and engine-out soot emissions, respectively, this is the first study to measure solid particle number (PN) emissions in addition to particle mass (PM). Furthermore, this study quantitatively evaluates the use of transient particle instruments for measuring particles from skip-fired operation in an optical single cylinder research engine (SCRE). Engine-out PN was measured using an engine exhaust particle sizer following a catalytic stripper, and PM was measured using a photoacoustic analyzer. The study improves on earlier preliminary emissions studies by clearly showing that DFI reduces overall PM by 76%–79% and PN for particles larger than 23 nm by 77% relative to conventional diesel combustion at a 1200-rpm, 13.3-bar gross indicated mean effective pressure operating condition. The degree of engine-out PM reduction with DFI was similar across both particulate measurement instruments used in the work. Through the use of bimodal distribution fitting, DFI was also shown to reduce the geometric mean diameter of accumulation mode particles by 26%, similar to the effects of increased injection pressure in conventional diesel combustion systems. This work clearly shows the significant solid particulate matter reductions enabled by DFI while also demonstrating that engine-out PN can be accurately measured from an optical SCRE operating in a skip-fired mode. Based on these results, it is believed that DFI has the potential to enable fuel savings when implemented in multi-cylinder engines, both by lowering the required frequency of active diesel particulate filter regeneration, and by reducing the backpressure imposed by exhaust filtration systems.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Enabling off-highway diesel engine downsizing and performance improvement using electrically assisted turbocharging

Internal combustion engine (ICE) downsizing through various turbocharging configurations is generally known by the powertrain design community as an effective means to reduce frictional losses, increase waste heat recovery, and improve fuel efficiency while increasing engine power density. However, often is the case that turbocharging strategies, including variable geometry turbochargers, and regulated two-stage turbochargers, incur the performance tradeoff between transient response and fuel economy (pumping losses) at high engine speeds. For off-highway vehicles having particularly transient and high-powered duty cycles, efforts to improve this tradeoff and increase operational flexibility have turned to evaluating various electrified air system architectures. In this study, a 4.5 L diesel-ICE configured with an electrically driven compressor (eBooster ® ) is placed in series with a conventional turbocharger and integrated into a 48 V mild-hybrid powertrain architecture. The objective of this powertrain configuration is to enable engine downsizing by 34%, replacing the current 6.8 L ICE platform with the hybridized 4.5 L ICE concept. The commercial 1-D simulation software GT-SUITE is used for powertrain system development and system optimization. Development and validation of the GT-SUITE model and air system controls is concurrently supported through experimental data collection. The simulation model development includes using machine learning methods for optimizing exhaust gas dilution, injection timing, and eBooster ® power to improve steady-state and transient brake-specific fuel consumption while minimizing criteria pollutant emissions. It was found that total specific fluid consumption over the standardized non-road transient engine duty cycle could be reduced by 18% over the current 6.8 L engine by using an optimized eBoosted 4.5 L engine. The hybridized 4.5 L engine concept concurrently showed sufficient transient response capability and nearly an order of magnitude reduction in duty cycle total soot production.

25 ENERGY STORAGE↗

DOE OSTI2023

Hierarchical multi-time-scale predictive thermal management and fuel optimization for heavy-duty compression ignition engines

For heavy-duty diesel engines, NO X emissions reduction is strongly constrained by fuel efficiency. This paper presents a hierarchical model predictive controller (H-MPC) for coordinated control of tailpipe NO X emissions and fuel consumption. The H-MPC uses the separation of slow and fast dynamics that exist in the engine and its aftertreatment system. The controller is synthesized with an architecture in which a high-level MPC uses a longer prediction horizon compared to the low-level predictive controller which tracks the high-level controller command and manages the thermal dynamics of the aftertreatment system. Engine load preview enables the high-level controller to estimate the desired catalyst temperature ahead of time and addresses the selective catalytic reduction (SCR) slow thermal dynamics. Calculated by the high-level controller, the intake manifold pressure, and the start of injection (SOI) crank angle is used as reference trajectories in the low-level controller that regulates fast dynamical behaviors such as engine out NO X emissions. Hardware-in-the-loop (HIL) validation of this integrated H-MPC on a rapid prototype controller shows that when the SCR catalyst temperature is above light-off temperature (warmed-up condition), the engine operation is shifted to operate with the best fuel economy since the warmed-up SCR can efficiently reduce the engine-out NO X emissions. Results indicate that up to 0.8% benefit in cycle averaged BSFC along with a 13% reduction in tailpipe NO X compared to a stock engine calibration can be achieved with the coordinated engine and aftertreatment system through H-MPC.

Engineering↗

DOE OSTI2018

Environmental Engineering for the 21st Century: Addressing Grand Challenges

Environmental engineers support the well-being of people and the planet in areas where the two intersect. Over the decades the field has improved countless lives through innovative systems for delivering water, treating waste, and preventing and remediating pollution in air, water, and soil. These achievements are a testament to the multidisciplinary, pragmatic, systems-oriented approach that characterizes environmental engineering. The future holds daunting challenges for human society and our environment. Populations are expanding, demand for resources is increasing, the climate is changing, and humanity’s impacts on the planet continue to mount. Will we be able to achieve a better quality of life for our growing population without compromising the ability of future generations to achieve the same? This study, authored by 18 of the nation’s leading environmental engineers, scientists, and policy experts under the auspices of the National Academies of Sciences, Engineering, and Medicine, outlines the crucial role for environmental engineers in this period of dramatic growth and change. The report identifies five pressing challenges of the 21st century that environmental engineers are uniquely poised to help advance: 1: Sustainably supply food, water, and energy, 2: Curb climate change and adapt to its impacts, 3: Design a future without pollution and waste, 4: Create efficient, healthy, resilient cities, and 5: Foster informed decisions and actions. The report’s vision is ambitious. The challenges ahead are substantial. Yet every day, environmental engineers are making progress, both by applying existing knowledge and skills and by advancing research and innovation to generate new insights and achievements. By refocusing and redoubling its efforts to advance practical, impactful solutions for humanity’s multifaceted, vexing problems, the field of environmental engineering can build on its past successes—and chart new territory—in the decades ahead.

42 ENGINEERING↗

DOE OSTI2020

Development of a Physics-Based Combustion Model for Engine Knock Prediction

The objective of this project is to improve the prediction of engine knock by developing a new combustion modeling framework. Engine knock is a limiting factor to constrain the increase of fuel efficiency for spark ignition (SI) engines in most passenger cars. Efforts to increase fuel efficiency, increasing the compression ratio or downsizing, lead to the increase in the tendency of the knock occurrence. The knock is an undesired ignition of the end-gas, unburned fuel/air mixture ahead of the spark-ignited premixed flame, resulting in rapid in-cylinder pressure rises and engine damages. The combustion modeling framework developed in this project can consider turbulence-chemistry interactions during end-gas ignition, while using a reasonably detailed chemical mechanism developed for ignition and combustion reactions under engine relevant conditions, and the subtle characteristics of spark-ignited flame propagation. It is developed in the context of large eddy simulation (LES), which can capture stochastic in-cylinder processes. The developed model is incorporated into a commercial software for engine simulation, CONVERGE CFD, as a user defined function, and validated. Engine knock and knock-free experiments as well as direct numerical simulation (DNS) of end-gas ignition in homogeneous turbulence are performed to help model development and provide data sets for model validation. With further validation, the developed model is expected to advance the predictive capability for engine knock simulations and thus contribute to improving the fuel efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Optical Engine Lockout System Design and Operation

Engine run days in the Diesel Combustion and Fuel Effects Lab are hectic. The long mental lists that must be kept by engine operators, paired with the tight time constraints between experiments, can cause operational issues that may be dangerous to personnel and/or cause damage to test equipment. Until now, a paper sign has been used to warn operators not to motor the engine when a foreign object has been placed inside of it. Unfortunately, this simple administrative control has failed in the past, motivating this effort to develop an improved system. The lockout system described in this document introduces an engineering control that, when activated, actually prevents the engine from being motored. The new system consists of a primary and a secondary control panel. Prior to an operator placing a foreign object into the cylinder, they press a button on the secondary control panel near the engine. This breaks the interlock circuit for the engine dynamometer and activates LEDs on both control panels to notify operators that a foreign object is present within the engine cylinder. Once the work is done and all foreign objects have been removed from the combustion chamber, two operators must be present to disable the system by simultaneously pressing the buttons on the primary and secondary control panels. Requiring a second operator to disable the system increases accountability and reduces the likelihood of potentially costly mistakes.

42 ENGINEERING↗

DOE OSTI2020

Evaluation of Engineered Form MOFs CaSDB and HKUST-1

Idaho National Laboratory (INL) and Pacific Northwest National Laboratory (PNNL) have studied different sorbents for the purpose of separating krypton (Kr) and xenon (Xe). PNNL has researched various metal-organic frameworks (MOFs) that have characteristics theoretically suitable for the separation. Based on computational analysis, PNNL chose Calcium–4,4’–sulfonyl dibenzoate (CaSDB) and Hong Kong University of Science and Technology MOF1 (HKUST–1). The raw MOFs are supplied in a powder form and must be incorporated into a robust engineered form to be viable for gas separation. In 2016, PNNL produced an engineered form of CaSDB by compressing and grinding the raw MOF material. This form was sent to INL for adsorption testing. Gentle mechanical agitation of the compressed form produced a large amount of powder, resulting in the conclusion that the form was not viable for the application. In 2019, INL successfully produced two engineered forms, CaSDB–EF1 and HKUST–EF2, by incorporating the active MOF powders into a polyacrylonitrile (PAN) binder. PNNL also produced two engineered forms, CaSDB–10pmma and HKUST–10pmma, by using polymethyl methacrylate (PMMA) as a binder. Surface area analysis indicated that the forms could be viable for separations in which the CaSDB–EF1 retained 84% of the raw CaSDB surface area and CaSDB–10pmma retained 48%. HKUST–EF2 retained all the raw HKUST–1 surface area, whereas HKUST–10pmma retained only 28%. Mechanical stability testing demonstrated that the PMMA forms formed a fine powder whereas, the PAN forms did not. In general, adsorption testing showed that CaSDB–10pmma had a lower Xe breakthrough capacity than CaSDB–EF1, but a higher saturation capacity at both room temperature and at 253 K. The CaSDB MOF was intended to be used as a room temperature sorbent to capture Xe. However, both CaSDB engineered forms displayed relatively short initial break through times. Reduced temperature increased the Xe capacity of both engineered forms. HKUST–1 was expected to be effective only at sub-zero temperatures. At 195 K, HKUST–10pmma had an initial Xe breakthrough capacity of 119 mmol/ kg, compared to HKUST–EF2 at 339 mmol/ kg. The saturation capacities were 275 and 383 mmol/ kg, respectively. HKUST–10ppm also had a lower Kr capacity of 1.7 mmol/kg, whereas the HKUST–EF had a Kr capacity of 3 mmol/ kg. Test results indicate that the PAN engineered forms are a more suitable choice for the complete separation of Xe and Kr, due to the increase in initial breakthrough capacity. CaSDB allows rapid breakthrough of Kr and Xe regardless of the type of engineered form. At 253 K, it is more viable, but is still not the most effective sorbent. HKUST–EF2 demonstrated viability for Xe capture at 195 K, which may merit further study, however it may be cost prohibitive.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2015

Affordable Development and Demonstration of a Small NTR Engine and Stage: A Preliminary NASA, DOE, and Industry Assessment

The Nuclear Thermal Rocket (NTR) represents the next evolutionary step in cryogenic liquid rocket engines. Deriving its energy from fission of uranium-235 atoms contained within fuel elements that comprise the engine's reactor core, the NTR can generate high thrust at a specific impulse of approx. 900 seconds or more - twice that of today's best chemical rockets. In FY'11, as part of the AISP project, NASA proposed a Nuclear Thermal Propulsion (NTP) effort that envisioned two key activities - "Foundational Technology Development" followed by system-level "Technology Demonstrations". Five near-term NTP activities identified for Foundational Technology Development became the basis for the NCPS project started in FY'12 and funded by NASA's AES program. During Phase 1 (FY'12-14), the NCPS project was focused on (1) Recapturing fuel processing techniques and fabricating partial length "heritage" fuel elements for the two candidate fuel forms identified by NASA and the DOE - NERVA graphite "composite" and the uranium dioxide (UO2) in tungsten "cermet". The Phase 1 effort also included: (2) Engine Conceptual Design; (3) Mission Analysis and Requirements Definition; (4) Identification of Affordable Options for Ground Testing; and (5) Formulation of an Affordable and Sustainable NTP Development Strategy. During FY'14, a preliminary plan for DDT&E was outlined by GRC, the DOE and industry for NASA HQ that involved significant system-level demonstration projects that included GTD tests at the NNSS, followed by a FTD mission. To reduce development costs, the GTD and FTD tests use a small, low thrust (approx. 7.5 or 16.5 klbf) engine. Both engines use graphite composite fuel and a "common" fuel element design that is scalable to higher thrust (approx. 25 klbf) engines by increasing the number of elements in a larger diameter core that can produce greater thermal power output. To keep the FTD mission cost down, a simple "1-burn" lunar flyby mission was considered along with maximizing the use of existing and flight proven liquid rocket and stage hardware (e.g., from the RL10-B2 engine and Delta Cryogenic Second Stage) to further ensure affordability. This paper provides a preliminary NASA, DOE and industry assessment of what is required - the key DDT&E activities, development options, and the associated schedule - to affordably build, ground test and fly a small NTR engine and stage within a 10-year timeframe.

Nuclear rocket engines↗

NASA NTRS2016

Modeling of Highly Instrumented Honeywell Turbofan Engine Tested with Ice Crystal Ingestion in the NASA Propulsion System Laboratory

The Propulsion Systems Laboratory (PSL), an altitude test facility at NASA Glenn Research Center, has been used to test a highly instrumented turbine engine at simulated altitude operating conditions. This is a continuation of the PSL testing that successfully duplicated the icing events that were experienced in a previous engine (serial LF01) during flight through ice crystal clouds, which was the first turbofan engine tested in PSL. This second model of the ALF502R-5A serial number LF11 is a highly instrumented version of the previous engine. The PSL facility provides a continuous cloud of ice crystals with controlled characteristics of size and concentration, which are ingested by the engine during operation at simulated altitudes. Several of the previous operating points tested in the LF01 engine were duplicated to confirm repeatability in LF11. The instrumentation included video cameras to visually illustrate the accretion of ice in the low pressure compressor (LPC) exit guide vane region in order to confirm the ice accretion, which was suspected during the testing of the LF01. Traditional instrumentation included static pressure taps in the low pressure compressor inner and outer flow path walls, as well as total pressure and temperature rakes in the low pressure compressor region. The test data was utilized to determine the losses and blockages due to accretion in the exit guide vane region of the LPC. Multiple data points were analyzed with the Honeywell Customer Deck. A full engine roll back point was modeled with the Numerical Propulsion System Simulation (NPSS) code. The mean line compressor flow analysis code with ice crystal modeling was utilized to estimate the parameters that indicate the risk of accretion, as well as to estimate the degree of blockage and losses caused by accretion during a full engine roll back point. The analysis provided additional validation of the icing risk parameters within the LPC, as well as the creation of models for estimating the rates of blockage growth and losses.

Simulation↗

NASA NTRS2017

NASA Systems Engineering Handbook

The update of this handbook continues the methodology of the previous revision: a top-down compatibility with higher level Agency policy and a bottom-up infusion of guidance from the NASA practitioners in the field. This approach provides the opportunity to obtain best practices from across NASA and bridge the information to the established NASA systems engineering processes and to communicate principles of good practice as well as alternative approaches rather than specify a particular way to accomplish a task. The result embodied in this handbook is a top-level implementation approach on the practice of systems engineering unique to NASA. Material used for updating this handbook has been drawn from many sources, including NPRs, Center systems engineering handbooks and processes, other Agency best practices, and external systems engineering textbooks and guides. This handbook consists of six chapters: (1) an introduction, (2) a systems engineering fundamentals discussion, (3) the NASA program project life cycles, (4) systems engineering processes to get from a concept to a design, (5) systems engineering processes to get from a design to a final product, and (6) crosscutting management processes in systems engineering. The chapters are supplemented by appendices that provide outlines, examples, and further information to illustrate topics in the chapters. The handbook makes extensive use of boxes and figures to define, refine, illustrate, and extend concepts in the chapters.

ENGINEERING MANAGEMENT; HANDBOOKS; MANAGEMENT METH↗

NASA NTRSDate not supplied

Lessons Learned in Systems Engineering Availability and Recommendations for Mission Technical Leaders

In spaceflight missions at Goddard Space Flight Center (GSFC), the Mission System Engineer (MSE) is the technical leader of the overall engineering team and also is the Independent Engineering Technical Authority. The responsibility of this role includes the definition of the mission design architecture, concept of operations, and mission requirements, management of risk throughout the development, and verification and validation of the final system performance and function amongst other duties. This responsibility inherently requires time management, enabling focus on a balanced development with appropriate risk. Time is the most valuable resource of the MSE. The system engineer’s availability to interact with the development team (often product or component design leads and technicians, often in different worksites) to discover and mitigate mission risks during development is key to mission success. This paper presents examples from Lunar Reconnaissance Orbiter, Landsat 9, and Neutron star Interior Composition ExploreR (NICER) which represent in-house and out-of-house hardware builds. These examples demonstrate how interactions between the Mission Systems Engineers and other project and partner engineers result in discovery of critical risks, leading to early mitigation with significant cost and performance savings. These three missions would have suffered test failures or on-orbit failures had their MSEs not set aside time to visit engineers and technicians that were working on key pieces of space flight hardware. Availability is more than just time; it is openness to listen to concerns and questions. It begins by building a level of trust in the team that it is safe to ask questions or share concerns without the fear of blame or additional workload. It also requires enabling informal conversations (over lunch, coffee, in the clean room, or at the team members desk, etc.) where key information can be exchanged, and team members may even provide an easy-to-implement mitigation idea for another subsystem. Availability is a highly valuable commodity and completely non-obvious to protect and optimize. The natural tendency of engineers is to keep themselves busy with solving problems that they know about. This paper is encouraging MSEs to resist this tendency to try and solve all the complex problems themselves and actively devote daily time to learning and solving problems that are found with informal communications with other team members.

Lessons Learned↗

NASA NTRSDate not supplied

How to Educate Decision Makers on the Value and Necessity of Modal Testing and Model Correlation: Tips for Young Engineers

Engineers need to effectively communicate the justification and value of their modal testing and model correlation in terminology familiar to decision makers as it relates to the program’s risk tolerance. This communication must relate to the program’s risk tolerance and the metrics used to judge the performance of both the program and individual decision makers. The challenge is the terminologies familiar to engineers and decision makers are quite different and seemingly unrelated. The engineering profession has developed a specific terminology to solve highly technical issues, which are many times themselves unique to very specific engineering problems. It is all too easy for engineers to believe that everyone in their organization, including the decision makers, has an intrinsic understanding of what they do and the value it brings to the program’s success. This is especially true for young engineers who have recently spent the last four plus years in an academic engineering learning environment, which has a highly technical research oriented atmosphere. Effective communication with decision makers is increasingly important as the technical breadth and practical program and project experience level for up and coming decision makers diminishes. It is not unusual for the decision makers to have technical knowledge in a domain different from structural dynamics (e.g., electronics or systems). Competition among satellite manufactures has increased the focus on programmatic cost and ability to deliver on schedule. NASA programs are also seeing more restrictive programmatic cost and schedule constraints, which impact both analysis and testing. It should also be noted that a comprehensive suite of tests are required to verify a satellite’s design capability with some margin. These tests include static strength verification tests, shock, acoustic, and vibration tests (sine and random) of systems, subsystems, and components. Each of these verification tests provide opportunities for model correlation and risk reduction. It is important to recognize dynamic loads/modal test models may not include all of the flight hardware (i.e., harness, coax, waveguides, connectors, etc.) and the previously mentioned tests are still required for qualification/verification of the design. This paper provides tips to young engineers on how to bridge this communications gap, have a better understanding of the environment in which decision makers operate, and assist them to better support successful missions. While this paper primarily focuses on modal testing and model correlation as related to spacecraft missions, the concepts and recommendations presented here are equally applicable to other fields such as aeronautics, automotive, power generation, etc.

Decision Maker↗

NASA NTRSDate not supplied

How to Educate Decision Makers on the Value and Necessity of Modal Testing and Model Correlation: Tips for Young Engineers

Engineers need to effectively communicate the justification and value of their modal testing and model correlation in terminology familiar to decision makers as it relates to the program’s risk tolerance. This communication must relate to the program’s risk tolerance and the metrics used to judge the performance of both the program and individual decision makers. The challenge is the terminologies familiar to engineers and decision makers are quite different and seemingly unrelated. The engineering profession has developed a specific terminology to solve highly technical issues, which are many times themselves unique to very specific engineering problems. It is all too easy for engineers to believe that everyone in their organization, including the decision makers, has an intrinsic understanding of what they do and the value it brings to the program’s success. This is especially true for young engineers who have recently spent the last four plus years in an academic engineering learning environment, which has a highly technical research oriented atmosphere. Effective communication with decision makers is increasingly important as the technical breadth and practical program and project experience level for up and coming decision makers diminishes. It is not unusual for the decision makers to have technical knowledge in a domain different from structural dynamics (e.g., electronics or systems). Competition among satellite manufactures has increased the focus on programmatic cost and ability to deliver on schedule. NASA programs are also seeing more restrictive programmatic cost and schedule constraints, which impact both analysis and testing. It should also be noted that a comprehensive suite of tests are required to verify a satellite’s design capability with some margin. These tests include static strength verification tests, shock, acoustic, and vibration tests (sine and random) of systems, subsystems, and components. Each of these verification tests provide opportunities for model correlation and risk reduction. It is important to recognize dynamic loads/modal test models may not include all of the flight hardware (i.e., harness, coax, waveguides, connectors, etc.) and the previously mentioned tests are still required for qualification/verification of the design. This paper provides tips to young engineers on how to bridge this communications gap, have a better understanding of the environment in which decision makers operate, and assist them to better support successful missions. While this paper primarily focuses on modal testing and model correlation as related to spacecraft missions, the concepts and recommendations presented here are equally applicable to other fields such as aeronautics, automotive, power generation, etc.

Decision Maker↗

NASA NTRSDate not supplied

Transient Optimization of a Gas Turbine Engine

Gas turbine engines are the primary power plants for modern commercial aircraft. Transients prompted by significant changes in thrust or power demand are common and unavoidable. Extreme transient scenarios such as those associated with a go-around during a landing attempt are possible and must be accounted for in the design of the engine and its controller. Engine transients tend to cause a reduction in compressor operability margin, which must be addressed by the engine control system and accounted for in the engine design to prevent events such as compressor stall/surge and combustor blow out. Transient operability concerns typically lead to compromises in the engine design that sacrifice efficiency and/or limit responsiveness. Transient operability is typically managed by logic that limits the fuel flow command. If this logic is not optimized, then the potential for valuable performance could be lost. This study presents a strategy for optimizing the transient limit logic and proposes a strategy for updating the control logic over the lifespan of the engine. The results demonstrate significant improvements in transient operability. For example, of the results at sea level static conditions demonstrated a 31% reduction in the usage of the high pressure compressor operability stack during a snap acceleration transient. Furthermore, a reinforcement learning algorithm is demonstrated to modify the transient logic as the engine degrades to minimize response time while respecting a prescribed compressor operability margin limit. A simple demonstration of the reinforcement learning algorithm resulted in a thrust response time reduction of ~11.8%.

transient↗

NASA NTRSDate not supplied

Transient Optimization of a Gas Turbine Engine

Gas turbine engines are the primary power plants for modern commercial aircraft. Transients prompted by significant changes in thrust or power demand are common and unavoidable. Extreme transient scenarios such as those associated with a go-around during a landing attempt are possible and must be accounted for in the design of the engine and its controller. Engine transients tend to cause a reduction in compressor operability margin, which must be addressed by the engine control system and accounted for in the engine design to prevent events such as compressor stall/surge and combustor blow out. Transient operability concerns typically lead to compromises in the engine design that sacrifice efficiency and/or limit responsiveness. Transient operability is typically managed by logic that limits the fuel flow command. If this logic is not optimized, then the potential for valuable performance could be lost. This study presents a strategy for optimizing the transient limit logic and proposes a strategy for updating the control logic over the lifespan of the engine. The results demonstrate significant improvements in transient operability. For example, of the results at sea level static conditions demonstrated a 31% reduction in the usage of the high pressure compressor operability stack during a snap acceleration transient. Furthermore, a reinforcement learning algorithm is demonstrated to modify the transient logic as the engine degrades to minimize response time while respecting a prescribed compressor operability margin limit. A simple demonstration of the reinforcement learning algorithm resulted in a thrust response time reduction of ~11.8%.

transient↗